Study on Slag Forming Route of Dephosphorization in Combined Blown Converter

In order to achieve the purpose of high-efficiency dephosphorization by single-slag method during the combined blown converter steelmaking process, the CaO-SiO2-FetO-MgO-MnO-P2O5 slag system was taken as the research object, and the slag-forming route of dephosphorization was studied. The effects of slag compositions on the liquidus and the contour map of phosphorus distribution ratios (recorded as Lp) were calculated by thermodynamics software FactSage, and then the theoretic slag-forming route of dephosphorization was obtained. The effects of slag compositions on dephosphorization rate and Lp were studied by a high-temperature experiment. Based on the results of the theoretic calculation and high-temperature experiment, the actual slag-forming route of dephosphorization by the single-slag process in the combined blown converter was obtained: The initial slag composition should be around 15.0%CaO-44.0%SiO2-41.0%FetO. The composition of high-efficiency dephosphorization slag should be around 50.8%CaO-24.2%SiO2-25%FetO. The final slag composition should be around 65.6%CaO-28.3%SiO2-6.1%FetO. After using the actual slag-forming route in the production, the dephosphorization rate was increased by 3.6%, and the consumption of slagging materials was reduced by 3.78 kg/t.

Recovery of Copper and Magnetite from Copper Slag Using Concentrated Solar Power (CSP)

On the one hand, copper slag is nowadays a waste in copper pyrometallurgy despite the significant quantities of iron (>40 wt. %) and copper (1 to 2 wt. %). On the other hand, solar energy, when properly concentrated, offers great potential in high-temperature processes. Therefore, concentrated solar power (CSP) could be used in the treatment of copper slag to transform fayalite into magnetite and copper sulfides and oxides into copper nodules. This is the objective of this paper. The results show that fayalite was partially decomposed into magnetite and silica. Moreover, copper nodules (65–85 wt. % Cu) were identified in the treated samples, while the initial slag, analyzed by X-ray diffraction, X-ray fluorescence, and SEM-EDX, did not show the presence of metallic copper. Finally, the treated copper slag was crushed and grinded down to 40 μm, and two fractions were obtained by magnetic separation. The magnetic fraction (85%) was mainly comprised of magnetite, while the non-magnetic fraction (15%) had 5–10 wt. % Cu. Considering the experimental results, 7.5–18 kg Cu/t slag might be recovered from the slag. A preliminary economic analysis, considering the current copper price, indicates that only the recovery of copper could represent a significant economic benefit (>30 €/t slag). Therefore, CSP might be a potential candidate for the treatment of copper slag to recover copper and iron.

Dephosphorization behavior of reduced iron and the properties of high-P-containing slag

Reduced iron (1.74% P) is produced from oolitic hematite ore by coal-based reduction and magnetic separation. To realize the comprehensive utilization of Fe and P, the dephosphorization behavior of the reduced iron is investigated in the presence of CaO–SiO2–FeO–Al2O3 slag. The P content of the final iron and the P2O5 content of the high-P-containing slag are determined, and the phase composition and P2O5 solubility of the slag are analyzed. The P content can be decreased to 0.2% when the initial slag has a basicity of 3.5 and contains 55% FeO and 6% Al2O3. The phases of the high-P-containing slag are mainly Ca2Al2SiO7, Ca2SiO4, Ca5(PO4)2SiO4, and FeO, and P exists in the form of Ca5(PO4)2SiO4. Excessively high basicity or low content of FeO and Al2O3 results in free CaO, which affects the dephosphorization results. The change rule of the intensity of the Ca5(PO4)2SiO4 diffraction peak agrees well with the dephosphorization indexes, which further verify the accuracy of the dephosphorization experiments. Moreover, the P2O5 content and P2O5 solubility of the high-P-containing slag reached as high as 14.41 and 94.54%, respectively, indicating that it can be used as a phosphate fertilizer.

Efficiency Estimation of the Bacal Siderites Using to Increase Stability of Steel-Melting Agregates Lining

During the melting processes in steel-melting aggregates, lining destruction takes place due to the Magnesium oxide of lining dissolution in slag. In this study, different materials containing Magnesium oxide have been introduced into slag to increase lining stability. Efficiency estimation of raw siderite (10-0 mm class) using for this aim is considered in the present work. Initial slag (basic capacity СаО/SiO2=2,1) of industrial ASM (Arc Steel Melting) was corrected by high magnesia introduction additives (siderite). Slag has been loaded into a magnesia crucible, heated up to 1700∘C, aged during 1 hour and cooled with the furnace. The final slag phase composition analysis detected considerable changes in it: increase of MeO-phase refractory with MgO prevalence (melting temperature 2800 ∘С) and replacement of monocellitic silicate component (CaO⋅MgO⋅SiO2, melting temperature 1498 ∘С) by larnite (β-2CaO ⋅SiO2 melting temperature 2130 ∘С). Crucible slag resistance was estimated by thinning of it walls. Experiment results confirmed affect of MgO content in slag to linings solubility in it. It was determined that siderite additives increase MeO-phase (melting temperature more than 2000 ∘С) content in slag approximately by 30 % that is rather essential for lining service period increasing. It is confirmed that siderite additives prolongate magnesia lining stability of steel-making aggregates. Keywords: Bacal siderite, refractory lining, steel-making aggregates, crucible, monocellit, magnesia

Distribution Behavior of Phosphorus in 2CaO·SiO2-3CaO·P2O5 Solid Solution Phase and Liquid Slag Phase

In this paper, the CaO-SiO2-FetO-P2O5 dephosphorization slag system during the premier and middle stage of the converter process was studied, the effect of slag composition on the distribution ratio and activity coefficient of P in the n·2CaO·SiO2-3CaO·P2O5 (recorded as nC2S-C3P) solid solution phase and liquid slag phase in the slag system was studied used by the high temperature experiment in laboratory, the theoretical calculation of thermodynamics, and the scanning electron microscope and the energy dispersive spectrometer (recorded as SEM/EDS). The research results show that when the FeO content in the liquid slag increases from 32.21% to 50.31%, the distribution ratio of phosphorus (recorded as LP) in the liquid slag phase increases by 3.34 times. When the binary basicity in the liquid slag increases from 1.08 to 1.64, the LP in the liquid slag phase decreases by 94.21%. In the initial slag, when the binary basicity increases from 2.0 to 3.5, the LP decreases by 70.07%. When FeO content increases from 38.00% to 51.92%, the LP increases by 6.15 times. When P2O5 content increases from 3.00% to 9.00%, the LP increased by 10.67 times. When the FeO content in the liquid slag increases from 32.21% to 50.31%, the activity coefficient of P2O5 in the liquid slag phase (recorded as γP2O5(L)) increases by 54.33 times. When the binary basicity in the liquid slag increases from 1.08 to 1.64, γP2O5(L) decreases by 99.38%. When the binary basicity increases from 2.0 to 3.5, the activity coefficient of P2O5 in the solid solution phase (recorded as γP2O5(SS)) in the solid solution phase decreases by 98.85%. When P2O5 content increases from 3.00% to 9.00%, γP2O5(SS) increases by 1.14 times. When the binary basicity decreases from 3.5 to 2.0, n decreases from 0.438 to 0.404. When the FeO content increases from 38.00% to 51.92%, n decreases from 0.477 to 0.319. When the P2O5 content increases from 3.00% to 9.00%, n decreases from 0.432 to 0.164. The decrease of binary basicity and the increase of FeO and P2O5 content in the initial slag can reduce the value of n and enrich more phosphorus in the solid solution phase. The results can not only provide a theoretical basis for industrial production, but also lay a theoretical foundation for finding more effective dephosphorization methods.

Removal of Copper from the Sulphide Copper Smelting Waste Slag

The applicability of chloridizing roasting for removal of copper from the sulphide copper smelting waste slag of the ”Karabashmed'” copper-smelting plant is investigated. Calcium chloride CaCl2 was used as chlorination agent. It is established that the chlorinating roasting of the initial slag presented by fayalite 2FeO∙SiO2, hasn't led to noticeable removal of copper. Considerable degree of removal of copper (more than 90 %) has been reached as a result of the chlorinating of preliminary oxidized slag in which fayalite was oxidized to form Fe2O3 and SiO2. Using a fractional factorial experiment 23–1, dependence of degree of copper removal from preliminary oxidized slag upon temperature of the chlorinating roasting, time of isothermal roasting period and content of CaCl2 was established. It is found that increase of temperature and of CaCl2 content leads to increase in degree of copper removal. The influence of time of isothermal roasting period in the studied interval (2–4 h) is statistically insignificant.

Room temperature zeolitization of boiler slag from a Bulgarian thermal power plant

A simple and cost-effective method was applied for the synthesis of zeolite composites utilising wet bottom boiler slag from the Bulgarian coal-fired thermal power plant ?Sviloza?, near the town of Svishtov. The method consisted of a prolonged alkali treatment at room temperature of this waste. Experimental techniques, such as scanning electron microscopy, energy-dispersive X-ray and X-ray diffraction analyses, are employed to characterize the initial slag and the final products with respect to their morphology, and elemental and mineral compositions. The composites synthesized in this way contained two Na-type zeolite phases: zeolite X (type FAU) and zeolite Linde F (type EDI). The zeolited products and the starting slag were tested as adsorbents for a textile dye (Malachite Green) from aqueous solutions. In comparison with the initial slag, the zeolite composite possessed substantially better adsorption properties: it almost completely adsorbs the dye in much shorter times. The results of this investigations revealed a new, easy and low cost route for recycling boiler slag into a material with good adsorption characteristics, which could find different applications, e.g., for purifying polluted waters, including those from the textile industry.

Mathematical Modeling of Draining of Dual-Strand Caster Tundish With Unequal Throughputs at United States Steel Corporation

Mathematical modeling of the tundish draining process was undertaken in response to the pouring of slag into the caster mold during draining of the dual-strand caster tundish at one of United States Steel Corporation’s plants before a tundish change. It was observed upon dumping of the tundish that the tundish skull was mostly slag on one side (the strand with the slag in the mold) and nearly all steel on the other. The current study attempted to reproduce the tundish draining event via mathematical modeling using the PHOENICS computational fluid dynamics software. The tundish draining was modeled for the case where the throughput of one strand was double that of the other strand. Transient flow modeling of the draining process included solving for the pressure and velocities for the two-phase slag-steel flows for two cases, one with a 6-inch thick slag layer and one with a 2-inch slag layer. The results showed that the draining process was affected significantly by the thickness of the initial slag layer. The simulations also qualitatively predicted the tendency of the slag to accumulate on the side with the higher throughput during tundish draining for a dual-strand tundish containing dams on both sides of the pouring area in the center.

PLANT GROWTH IN COAL GASIFICATION SLAG-AMENDED MEDIA

Coal gasification slag is an ash byproduct remaining after the volatization process. This material is currently under utilized. A series of experiments were conducted to determine the suitability of coal gasification slag as a growing medium or growing medium amendment. Chrysanthemums, lettuce, poinsettias and some bedding plants were grown in slag or slag amended media in an ebb and flow fertigation system. Slag alone has a high pH and initial slag samples had some very small particle sizes. Plant growth in slag alone was poor because of high pH and low aeration. When slag was amended with moss peat, the pH was lowered to an acceptable range and the aeration was better. Plant growth in peat-slag media was equal to plant growth in a peat-perlite mix. Media composed of peat-slag and bark were also successful in producing crop growth equal to peat-perlite. There were no nutritional problems growing in slag amended media except that boron uptake by chrysanthemum was greater than in other media. Eliminating the small particle sizes by washing the slag makes the slag easier to handle, but does not produce crop growth equal to slag amended media.